Method and device for making up metal bands into hollow rails

ABSTRACT

Apparatus and method for making at least two metal bands into a hollow rail, e.g. for door and window frames, wherein the bands are simultaneously drawn by a tractive force acting from the formed end, e.g. by a power-operated reciprocal clamp, through non-driven roll-type forming tools which shape the bands into profiles while under the tractive force so that the bands are strengthened and straightened in at least some longitudinal zones. While being drawn through the forming tools a non-metallic elastic shim liner is fed and applied to the edges of at least one of the bands and after both bands have been profiled, they are pressed together, by appropriate guiding and shaping tools, whereby the longitudinal edges of the bands are connected together by a folded welt that completely encloses the shim liner while the latter prevents friction metallic contact between the two bands.

United States Patent Falkner [451 Sept, 12, 1972 [72] Inventor: RaimundFalkner, Roppen/Tirol,

Austria [73] Assignee: Rapena Patent & Verwaltungs AG, I

Vaduz, Liechtenstein [22] Filed: Aug. 28, 1970 [21] App1.No.: 67,801

[30] Foreign Application Priority Data Aug. 28, 1969 Germany... ..P 1943 826.7

[52] US. Cl. ..29/155 R, 29/200 B, 29/430 [51] Int. Cl. ..B23p 17/00,B23p 19/00 [58] Field of Search....'.29/l55 R, 200 B, 200 R, 429, 29/430[56] References Cited UNITED STATES PATENTS 2,678,488 5/1954 Erzer..29/l55 R 3,505,719 4/1970 OMalley et al ..29/200 B PrimaryExaminer-Thomas H. Eager Attorney-Cushman, Darby & Cushman [57] ABSTRACTApparatus and method for making at least two metal bands into a hollowrail, e.g. for door and window frames, wherein the bands aresimultaneously drawn by a tractive force acting from the formed end,e.g. by a power-operated reciprocal clamp, through nondriven roll-typeforming tools which shape the bands into profiles while under thetractive force so that the bands are strengthened and straightened in atleast some longitudinal zones. While being drawn through the formingtools a non-metallic elastic shim liner is fed and applied to the edgesof at least one of the bands and after both bands have been profiled,they are pressed together, by appropriate guiding and shaping tools,whereby the longitudinal edges of the bands are connected together by afolded welt that completely encloses the shim liner while the latterprevents friction metallic contact between the two bands.

21 Claims, 35 Drawing Figures PATENTEDSEP 12 I972 SHEET 1 [1F 8 lip-I22.

PATENTEDSEP 12 m2 ill=ilil l il w? a \Y. v a Q v R. QN QM y w QM -S RNm. \N U ml R\ Q Profiles in the most diverse forms, as well as hollowrails for doors and windows, have been known for a long time past.Similarly, there are numerous methods for the making of such profiles,but they generally show considerable shortcomings from the point of viewof economy. Most of the known methods are too complicated to permit theobtention of low-cost profiles. Moreover, the known hollow rails usuallyhave insufficient thermal insulation which especially in the case ofwidow-frames results in the formation of perspiration water.

Against that, the present invention is concerned with a method thatpermits an economical manufacture of hollow rails with improvedcharacteristics by continuous processing of at least two metal hands bymeans of roll forming tools, joining the lateral longitudinal edges byfolded welts. It is characteristic for this method that the metal bandsare simultaneously drawn through the rotating forming tools by atractive force acting from the formed end and that they are not exposedto any advance force in the roll forming tools, but they are formed intorails by a pressureacting on the surface of the bands, and while underthe influence of the longituthrough the forming installations, notdriven, located there for the profiling of metal bands, then through agreasing station located before the forming installation, throughguiding organs to the joining of the travelling, profiled mental bandsin a mutual position determined in advance, and through other forminginstallations, not driven, to the strengthening of the longitudinaledges of the metal bands by means of folded welts.

In the following, the method according to the invention is described indetail with regard to exemplified embodiments of hollow rails and partsof the device according to the invention by the help of the schematicdrawings.

These drawings show:

FIGS. 1, 1A and 1B are lateral or side views of successive portions ofthe two working paths of the device.

FIG. 2 is a transverse sectional view of a section of 'the millingequipment shown in FIG. 1.

V path at the right-hand side of FIG. 1.

dinal feed they are strengthened and straightened at least in some ofthe longitudinal zones of their structure. Hereupon the longitudinaledgesof at least one profile are provided with an elastic nonmetallicshim liner, then the profiles are pressed together, bordered on at-leastone of their longitudinal edges and, avoiding any metallic contact,frictionally connected between the longitudinal edges embracing oneanother by a folded welt which encloses the shim liner all round, isunder initial stress and secured against transverse forces. The hollowrail is made in one operation.

The method according to the invention can be 'so performed that themetal bands are either drawn forward by the tractive force each timeonly on a stretch determined in advance and then .shaped into theproposed hollow rail, which is then cut off and the cycle of operationis automatically repeated, or they are continuously drawn forward andtransformed into the proposed hollow rail from which each time apredetermined length is separated, without however interrupting thedrawing process. The separation can be made either with a straight cutor by means of an adjustable mitering device. The elastic shim liner canbe fed to the metal bands in the form of a profile and then united withthe longitudinal edges of a band, or at least one of the bands can,already before or during its forming, be provided with an elasticcoating on its longitudinal edges. The longitudinal edges can beprovided with rugosities, such for instance as milling or perforation,so as to ensure a better adhesion of the elastic shim liner.

Furthermore, the invention is concerned with a device for theperformance of this method with at least two working paths and alongthem with installations for the transformation of metal hands intoprofiles. The device is characterized by a drawing station located atits end, adapted to at least one profile to be manufactured, for thesimultaneous drawing of at least two metal bands off the magazine rollsand for conveying the same along the pertaining working paths and FIG. 4is a transverse sectional view through onev of the forming stations inthe lower path shown at the ri t-hand side of FIG. 1.

FIGS. 5a, b, c and d are transverse sectional views through successiveforming stations shown in the lower path at the left-hand side of FIG.1A.

FIGS. 6a, b, c, and d are transverse sectional views through successiveforming stations shown in the lower path at the left-hand side of FIG.1A.

FIG. 7 is a plan view, with parts broken away, of the installation shownat the right-hand side of FIG. 1A for threading .up and shaping theelastic shim.

FIG. 8 is a transverse sectional view taken substantiallyon line 8-8 ofFIG. 7.

FIGS. 90, b, c and d are vertical sectional views through successivestations shown at the left-hand side of FIG. 1B for joining of thetwo-part profiles.

FIG. 10 is a transverse sectional view of the pull down claws of theinstallation shown at the right-hand side of FIG. 1B.

FIG. 11 is a lateral view of a modified form of the pull downclaws ofthe installation shown at the righthand side of FIG. 1B.

FIGS. 12a, b, and c are views corresponding to FIGS. 3a, b and cshowing-a modified form of the invention.

FIGS. 13a, b and c are views corresponding to FIGS. 5a, 0 and d showinga modified form of the invention.

FIG. 14 is a transverse sectional view of a forming station withthree-part profile mill cutters.

FIG. 15 is a view of housing columns for forming stations seen in thedirection of the metal bands coming down.

FIG. 16 is a lateral view of the housing columns shown in FIG. 15.

FIG. 17 is a view of an exemplified embodiment of a drawinginstallation.

FIG. 18 is a transverse sectional view of an exemplified embodiment of asymmetricalhollow rail.

FIGS. 19-25 are transverse sectional views showing various stages ofoperation during the manufacture of the hollow rails shown in FIG. 18.

FIG. 26 is a transverse sectional view of an exemplified embodiment ofan unsymmetrical hollow rail.

FIGS. 27 to 33 are end profile views showing various stages of operationduring the manufacture of the hollow rail shown in FIG. 26.

In the following, the present method if first described in connectionwith the manufacture of a hollow rail fromthe shape shown in FIG. 9d.Here two metal bands one beneath the other, preferably in aluminum, aresimultaneously drawn through rotating forming tools by a tractive forceacting from the formed end, thus on the finished hollow rail. But thesetools exercise no advance force but pressure on the surface of the metalbands. The upper metal band is first formed into a U profile (FIGS. 3a,b and open downwards, and the two legs are chamfered outwards 90 (FIGS.5a, b, c and d). During this process the underneath metal band is formedinto a lower and narrower U profile, open downwards, with wider legschamfered outwards (FIG. 4). Then on the edges of the upper U profilethat are turned outwards a shim liner is drawn up, consisting of anelastic band folded up lengthwise (FIG. 7, 8), the lower parts of whichtower inwards above the chamfered edge. Then the U profiles thus madeare pressed one upon the other with theirchamfered longitudinal edges,and those of the underneath U profile are bent approx. 180 around thelongitudinal edges of the upper U profile, which are coated with theshim liner (FIGS. 9a and c), and are pressed into the elastic shim linerwhich is enclosed all round (FIG. 9d).

During their transit rolling through the rotating forming tools, themetal bands are under a considerable longitudinal traction, they arestrengthened in their structure at leastin some of the longitudinalzones by the forming tools, which only press on the surface of the bandbut do not exercise any upsetting advance force on the same, and theyare at the same time straightened by the tractive force. This drawingprocess during the manufacture of profiles endows the part-profiles and,after their joining, the finished hollow rail with an accuracy to sizeand a mechanical strength which are superior to those of the hollowrails made by means of driven rotating forming tools, which exert anadvance force on the metal bands and/or the part-profiles, upset thematerial and necessitate a subsequent straightening of the finishedhollow rails.

The hollow rail manufactured according to the method herein describedshows no metallic contact on the longitudinal edges embracing oneanother between the upper and the lower part-profiles, owing to the shimliner for which a nonmetallic elastic material is used. Thischaracteristic results in a considerable thermal insulation between thetwo part-profiles, which in the case of windowand door-frames preventsthe formation of undesired perspiration water and greatly reduces thethermal losses from inside to outside and vice versa. Moreover, thetransmission of sound between the part-profiles is considerably damped,which practically prevents the occurrence and/or transmission of noises,especially those caused by the opening and shutting of windows anddoors. As the insulating shim liner is practically enclosed all round bythe folded border of the lower part-profile, neither wetness nor lightcan affect the shim liner, so it practically has an unlimited lifetime.

The fact that the lower partprofile is pressed with its benbaround edgeinto the elastic shim liner results in an elastic initial stress of thefolded welt, so that the part-profiles forming the hollow rail arefrictionally connected one with the other. Known hollow rails formed ina similar way but with metallic contact between the part-profiles alongtheir folded welt have no tensional connection at this spot, areconsiderably inferior to the hollow rails manufactured according to thepresent method as far as mechanical strength is concerned and cannot beutilized as load-bearing constructional elements. The hollow railsmanufactured according to the method herein described are also securedagainst transverse forces, since the elastic shim liner extends alsoalong the leg of the lower U profile that laps into the inside space ofthe upper U profile and frictionally connects the lower U profile withthe upper one.

In the following, an exemplified embodiment of a device for themanufacture of the above hollow rail is described in detail. As shownschematically in FIG. 1, this device has two working paths 1 and 2 whichare disposed one beneath the other and serve for forming the two metalbands 4 and 5 which are drawn off the two magazine rolls 6 and 7. Thebands 4, 5 are turned back through the rollers 8, 9 and pass through agreasing station 10 which is for instance constructed as a reservoir andcontains a lubricant, such for instance as bring about that thelongitudinal edges of the band 4 1 are knurled on both sides and thoseof the band 5 only on the upper side. If desired, instead of theknurling installations can be used differently constructed stations inorder to provide the longitudinal edges with rugosities or perforations.

FIG. 1-4 show the rollers located along the working paths 1 and 2, whichserve for forming the bands 4, 5. Three rollers 12, 13, 14 freelyrotating around their axes are acting on the band 4, transforming itaround the fixed forming core 15 into a U profile open downwards. Theforming of the band 5 takes place by means of a pair of profile millcutters 16, 16' along the working path 2, for which no forming core 15as in the case of the rollers of the working path 1 is necessary.

The profile mill cutters 16, 16 also are individually freely rotatingaround their axes.

The upper U profile is, as indicated in FIGS. 1A and 5, along theworking path I pressed by three freely rotating rollers 17, 18, 19,acting together from time to time, from above and from the sides againstthe forming cores 23, 23, 23" which during the passage of the U profilebring about, by means of chamfered flanks, a lateral outward folding ofthe protruding longitudinal edges 21, 22 of the legs. The rectangularityof the chamfered edges is ensured by further drawing of the profile 4through two pointed rollers 24, 25.

The two pairs of rollers 20, 20' of FIG. 6 located along the workingpath 2 for further forming of the flat U profile 5 with widelongitudinal edges are constructed with only such a width that the twowide longitudinal edges 26, 27 laterally protrude and while drawingthrough the profile 5 these bead edges 28,29 can be straightened out bymeans of two oblique, freely rotating rollers 30, 31.

The longitudinal edges 21, 22 of the upper profile 4, which are bentoutwards, are now provided with an elastic shim liner which, accordingto FIGS. 1A, 7 and 8, in the form of two longitudinally folded plasticbands, is drawn off the magazine rolls 32, opened by the deflectors 35,36 and drawn over the longitudinal edges 21, 22. Owing to the knurlingby the rollers 11, the static friction of the plastic bands is so strongthat they cannot shift.

Now, as shown in FIGS. 1B, 9a, b and c, the two U profiles are fittogether, pressed together with their longitudinal edges and thestraightened bead edges 28, 29 of the profile 5 are, by interaction withthe three freely rotating rollers 37, 38, 39 and the freely rotatingprofile cut millers 40 as well as with a fixed steel core 40', bentaround the longitudinal edges 21, 22 which are lined with the shim liner33, 34. During this forming process the fixed wedge gibs 41, 42 areused, which ensure a gradual bending over of the bead edges 28, 29, asshown in FIG. 9b, by forming a rim 29' and thereby prevent any pushingout or in or damaging of the shim liners 33, 34. The bending over of thebead edges 28, 29 takes place according to FIG. 90 by means of thefreely rotating rollers 43. The pressing of the bead edges 28, 29 intothe elastic shim liner takes finally place, as shown in FIG. 9d, bymeans of the freely rotating rollers 44. An especially solid folded weltis obtained by perforating the longitudinal edges 21, 22 of the profile4 and milling or dotting the surfaces of the bead edges 28, 29 that arefacing the shim liners 33, 34.

The tools located along the working path 1 for forming the metal band 4are indicated above as freely rotating rollers which act together withfixed forming cores or wedge gibs. For forming the metal band 5, anupper and a lower profile mill cutter are provided at some spots. In apreferred exemplified embodiment of a device for the manufacture ofhollow rails according to the present method mostly such profile millcutters are used as those described in the following with the aid ofFIGS. 12 to 15. If for instance a U profile open downwards is to be madefrom the metal band 4, as explained above by the help of the upper partsof FIG. 14, 4 and 5, the rollers 12, 13, 14 freely rotating around theiraxes in each case act together with a counterroller 45 which is alsofreely rotating. For chamfering the two lower ends of legs, besides thethree freely rotating rollers 17, 18, 19 there is a three-partedcounterroller 46, 46", 46", the three parts of which are individuallyfreely rotatable around a common axle, independently of each other. Asshown in Fig. 14, in each case three-parted counterrollers withadequately shaped, individually freely rotating parts are used for thefinishing of the U profile. As shown in FIG. 14, profile mill cuttersconsisting of three or more parts that are in each case freely rotatableindependently of each other around a common axle can be disposed also inpairs above and below the metal band.

In a preferred exemplified embodiment of a device for the manufacture ofhollow rails according to the present method the roll forming toolsconsisting of onepart or multiple-part profile mill cutters and rollers,as shown in FIGS. 15 and 16, are disposed freely rotating at the frontend of each of the carrying bolts 70, 71 above and below the metal band4 and at the front end of each of the carrying bolts 72, 73 above andbelow the metal band 5. The rear parts of these carrying bolts are ineach case held by a massive socket 74, 75, 76, 77.

All four sockets are mounted on the two housing columns 78, 79, wherethe sockets 75, 76 are fixed by means of the clamping jaws 80, 81 and80', 81' respectively in their unique position on the housing columns 78and 79, whereas the sockets 74 and 77 are fixed by means of the bearingbushes 82, 83 and 82, 83 respectively, which are movable along thehousing columns 78, 79. In FIG. 16 only the setting mechanism for thebearing bush 83 is shown and it can for instance consist of an elevatingscrew 84 on the hand wheel 85 which is tumable in a nut 86 fixed on thehousing column 78 and can displace the bearing bush upwards ordownwards. A similar setting device is fixed on the back housing column79 and is connected with the elevating screw 84 eg by means of a chainso that when turning the hand wheel 85 thetwo bearing bushes 83 and 83'are simultaneously displaced along the housing columns 78 and 79respectively. Thus the profile mill cutters can relatively be adjustedone to the other and to the metal bands 4 and 5 running through. Thedescribed disposition of the profile mill cutters self-supporting on theend of each of the carrying bolts also permits a quick exchange of oneor several profile mill cutters, which makes possible repairs easy and,in particular, permits the change-over of the whole device to theproduction of another hollow rail within a short time. Of course,besides the profile mill cutters described above, also the necessaryfreely rotating lateral rollers are mounted on the housing stands, whichrollers are also relatively adjustable to the metal bands or the profilemill cutters respectively and they are so mounted on the self-supportingends of the corresponding carrying bolts that they can easily beexchanged.

According to the present method, the two metal bands 4, 5 are drawn fromthe formed end, thus from the finished hollow rail, through all theforming stations forwards along the working paths. An exemplifiedembodiment of an adequate drawing device, as represented schematicallyin FIG. 17, shows the drawing station 85 which is moved from an initialposition on the driving mechanism 87 by the lead screw 88 along theguide rail 86 to an end position determined by the limit switch 89. Thelimit switch, which can be fixed at any point along the guide rail 86,effects, when actuated by the drawing station 85, the switching off ofthe driving mechanism 87 and a temporary drawdown of the separatingdevice 90 along the column 91, so that the circular saw 92 cuts off thefinished hollow rail 93. Subsequently the clamping mechanism 94 on thedrawing station 85 is opened for the hollow rail 93, the drawing stationis brought back to its initial position, the cut-off piece of the hollowrail is taken away, the clamping mechanism 94 is again closed around theend of the hollow rail and the driving mechanism 87 is again switchedon, whereby a new cycle of the drawing process, and thus of the hollowrail production, is started. By means of the column 91 the separatingdevice can be swivelled for the separation of the hollow rail with amiter cut, so that finished hollow rails that are already cut in mitercan be manufactured in any length without loss by cutting.

According to another exemplified embodiment, in conformity with FIGS. 18and 10, a continuously working drawing mechanism 47 can be provided withtwo endless roller chains 48, 49. These endless roller chains 48, 49 runover wheels 50, 51 and are provided with profile-gripping claws 52, 53.Preferably the profilegripping claws 52, 53 are so designed that byusing elastic buffers 59, 60, 61 no deformations of the finished profile4, can occur. In order to ensure a uniform gripping of the finishedprofile 4, 5 pressure shoes 54, 55 are provided which under the effectof adjustable springs 56, 57 exert a pression on the roller chains 48,49 and thus on the profile-gripping claws 52, 53. The drawing device 47is followed by a cutting device with swivelling saw, which needs nofurther description as such separating devices are well known. The sawswivelling and therefore can make miter cuts in various directions. Itturned out to be advantageous to provide the elastic buffers 59, 60 ofthe profilegripping claws, or the profile-gripping claws themselves, asshown in FIG. 22, with levers62 inclined towards the running directionof the profile, so that when moving the chains 48, 49 in the directionof arrow on purpose to advance the hollow rail a clamping effect arisesbetween the buffers 59, 60 and the profile PP 1 The present method andsome exemplified embodiments of a device are explained above with theaid of a relatively simple hollow rail of box-type design. However, muchmore complicated hollow rails, such as those described in the following,can also be manufactured in this way. These two hollow rails practicallymeet all requirements regarding windowand doorprofiles in modernbuildings.

For the manufacture of the hollow rail shown in FIG. 18, in the lastsequence of operation, according to the present method the upper of twometal bands 100, 101 moved one beneath the other is formed into a Uprofile open downwards, then its legs are chamfered outwards 90 at thelower end and further bent upwards at their outer edge 104, 105 (FIG.19). Then a band-shaped elastic shim liner 102, 103 with a wide baseplate and a hook-shaped, projecting rib 106 and 107 respectively, whichembraces the corresponding edge is drawn onto the two edges 104, 105.During this process, the lower metal band 101 is transformed into a wideU profile, open upwards, (FIG. by bending up its longitudinal edges108,109. The two upright longitudinal edges are bent outwards approx. 90below (FIG. 21) and by two other nearly rectangular folding welts aU-shaped groove 110 and 111 respectively is formed on both sides (FIG.22). By further bending of the inside edges 112, 113 the twolongitudinal edges 108, 109, which are now both provided with a U-shapedgroove, are again righted and the U-shaped grooves are then compressedinto a dovetailed groove 114 and 115 respectively (FIG. 24) and theextremities of the legs 116, 117 are flanged inwards approx. 45. Now thelower U profile is pressed against the base plates of the shim liners102 and 103 which are on the longitudinal edges 104, 105 of the upper Uprofile, the longitudinal edges 108, 109 of the lower U profile are bentupwards round the two top edges of the base plates (FIG. 25), the twolongitudinal edges 108, 109 provided with the dovetailed grooves 114,115 are pressed into the upper sides of the shim liners 102, 103 and thelongitudinal edges 104, embraced by the ribs 106, 107 of the shim linersare pressed around the upper U profiles.

welt of the longitudinal edges 108, 109 is under initial stress, thusthe two profiles are frictionally connected one with the other. Thelongitudinal edges 104, 105 of the upper U profile, which are surroundedby the ribs 106, 107 of the shim liners and held by the longitudinaledges 108, 109 of the lower U profile, ensure great resistance totransverse forces. The hollow rail manufacturedin the way describedabove, whose two partprofiles have no metallic contact with one'another, has all the advantages mentioned in connection with thebox-shaped hollow rail (FIG. 9d) with regard to thermal and soundinsulation. The dovetailed grooves 114, in the upper side of the foldedwelts on both sides permit the fitting of sealing profiles which aredesirable in the case of windows and doors. If such sealing profiles arenot wanted, the dovetailed grooves can, of course, be renounced.

However, the present method permits not only the manufacture of hollowrails that are formed symmetrically with a central axis according toFIGS. 9d and 18, but also the making of unilateral profiles. An exampleof a hollow rail of such kind in one of the last courses of manufactureis shown in FIG. 26. This hollow rail is also manufactured with theutilization of two metal bands 118, 119 moved one beneath the other, butthey are now simultaneously formed into the mirror image of one another.First the lower metal band 118 is bent upwards 90 at its left-handlongitudinal edge 120 (FIG. 27), the upper part is bent outwards further90 (FIG. 28), whereas the right-hand longitudinal edge 121 of the metalband 118 is chamfered downwards. By two further nearly rectangularchamferings of the lefthand longitudinal edge 120, there is created a U-shaped groove 122 (FIG. 29), which is further bent around its insideedge 123 and thereby the longitudinal edge 120 again righted. Then theU-shaped groove is compressed into a dovetailed groove 124, theextremity of the leg 125 is flanged inwards approx. 45 (FIG. 31) and theright-hand part 126 of the metal band 118 with the longitudinal edge 121is bent upwards (FIGS. 30 and 31). Finally the leg 126 is put upright,so that the longitudinal edge 121 runs nearly horizontally, and then theoutside longitudinal edge 127 if flanged downwards approx. 90 (FIG. 32)and the left-hand longitudinal edge 120 is bent inwards approx. 45.

The upper metal band 119 has undergone an analogous forming in mirrorimage (FIG. 33). It is provided with a right-hand longitudinal edge 128,bent inwards approx. 45, which has a dovetailed groove 129 and a legedge 130 flanged inwards and is formed into a vertical leg 131 and anearly horizontal left-hand longitudinal rim 132 with a longitudinaledge 133 bent over approx. 90. Now two band-shaped elastic shim liners134, 135, each provided with a wide base plate and a hook-shaped,projecting rib 136 and 137 respectively embracing the longitudinal edges127 and 133 respectively, are drawn onto the outermost longitudinaledges 127 and 133 of the longitudinal rims 121 and 132 respectively. Thetwo profiles thus prepared are joined, pressed together, the left-handlongitudinal rim 120 of the lower profile is bent upwards around theoutside edge of the shim liner 135 and its longitudinal rim 129 providedwith the dovetailed groove is pressed into the upper side of the shimliner 135 and around the longitudinal rim 133 of the upper profile,which is embraced by the rib 137- of the shim liner. At the same timethe right-hand longitudinal rim 128 of the upper profile is bentdownwards around the outside edge of the shim liner 134 and thelongitudinal edge 128 provided with the dovetailed groove is pressedinto the lower side of the shim liner 134 and around the longitudinaledge 127 of the lower profile, which is embraced by the rim- 136 of theshimliner.

This profile is also manufactured in one operation according to thepresent method and has all the advantageous characteristics mentionedabove in connection with the hollow rails according to FIGS. 9d and 18.

The present method is, of course, not limited to the three forms ofhollow rails described in detail in the foregoing paragraphs. It canalso be employed for the manufacture of a great number of hollow railsof different forms and also for the forming and joining of more than twometal hands into hollow rails.

I claim:

1. Method for making up at least two metal bands into a hollow rail bymeans of roll forming tools and by joining the lateral edges by means offolded welts, characterized by the fact that the metal bands aresimultaneously drawn through the rotating forming tools by a tractiveforce acting from the formed end, in the roll forming tools withoutadvance force they are formed into profiles only by a pressure acting onthe surface of the bands and at the same time under the effect of thelongitudinal feed they are strengthened in at least some zones of theirstructure and thereby straightened, the longitudinal edges of at leastone of the profiles are provided with a nonmetallic elastic shim linerand then the profiles are pressed together, bordered on at least one oftheir longitudinal edges and without metallic contact frictionallyconnected with one another between the longitudinal edges embracing oneanother by means of a folded welt embracing the shim liner all round,which folded welt is under initial stress and secured against transverseforces, and thus the hollow rail is made in one operation.

2. Method according to claim 1, characterized by the fact that the metalbands are in each case drawn forward by the tractive force on a stretchdetermined in advance and formed into the proposed hollow rail, which isthen separated, and hereupon the cycle of operation is automaticallyrepeated.

3. Method according to claim 1, characterized by the fact that the metalbands are continuously drawn forward and formed into the proposed hollowrail from which each time a predetermined length is separated withoutinterruption of the drawing process.

4. Method according of claim 1, characterized by the fact that theelastic shim liner is fed to the metal bands in the form of a profileand united with the longitudinal edges of one band.

5. Method according to claim 1, characterized by the fact that at leastone of the bands is provided already before, or during, its forming withan elastic coating on its longitudinal edges.

6. Method according to claim 1, characterized by the fact that thelongitudinal edges of at least one of the bands is provided withrugosities, in particular with knurling or perforation.

7. Method according to claim 1, characterized by the fact that the upper(4) of two metal bands (4, 5) moved one beneath the other is formed intoa U profile open downwards and the two legs are chamfered outwards (21,22), during which process the underneath metal band (5) is transformedinto a lower and narrower U profile with wider longitudinal rimschamfered outwards (26, 27), then a shim liner consisting of an elasticband doubled longitudinally (33 34) is drawn onto each of the rims (21,22) turned outwards of the upper U profile, the lower parts of the shimliner protruding inwards above the chamfered edge up to its end, theaforesaid two U profiles are pressed upon one another and the rims (28,29) of the lower U profile are bent approx. 180 around the longitudinalrims (21, 22) of the upper U profile, which longitudinal rims are coatedwith the shim liner, and then pressed into the elastic shim liners (33,34) which are enclosed all round.

8. Method according to claim 1, characterized by the fact that the upperof. two metal bands (100, 101) moved one beneath the other is formedinto a U profile open downwards, the two legs of which are chamferedoutwards 90 at their lower ends and at their outer rims (104, 105) arefurther bent upwards 90, then a band-shaped elastic shim liner (102,103) with a wide base plate and hook-shaped protruding ribs (106, 107)embracing the rims (104, 105) is drawn onto the rims (104, 105), duringwhich process the lower metal band (10) is formed into a broad U profileopen above with upright longitudinal rims (108, 109) which are both bentoutwards 90 and by two further nearly rectanagular folding welts areprovided with a U- shaped, groove (110, 111), then they are further bentaround the inside edges (112, 113) and set vertically, the aforesaidU-shaped grooves are then compressed into dovetailed grooves (114, 115)and flanged outwards on the longitudinal edges (114, 115), hereupon thelower U profile is pressed against the base plates of the shim liners(102, 103), which are on the longitudinal rims (104, 105 of the upper Uprofile, the longitudinal rims (108, 109) of the lower U profile arebent upwards around the two top edges of the base plates and the twolongitudinal rims (108, 109) provided with the dovetailed grooves (114,115) are pressed into the upper sides of the shim liners (102, 103) andaround the longitudinal edges (104, 105) of the upper profile, which areembraced by the ribs (106, 107) of the shim liners.

9. Method according to claim 1, characterized by the fact that two metalbands (118, 119) moved one beneath the other'are simultaneously formedinto the mirror image of one another, during which process the lowermetal band (118) is bent upwards 90 at its lefthand longitudinal rim(120) (FIG. 32) and this leg is further bent outwards 90, by two furtherrectangular chamferings is provided with a U-shaped groove (122), byfurther bending around its chamfered inner edge (123) is righted again,the U-shaped groove is compressed into a dovetailed groove (124) and theoutermost edge of the leg (125) is bent inwards, whereas the metal band(118) is chamfered downwards 90 at the right-hand longitudinal rim andthen together with this leg (121) bent over 90, put vertically andflanged downwards 90 at the outermost longitudinal edge (127), then aband-shaped elastic shim liner (134) with a wide base plate and ahook-shaped protruding rib (136) embracing the longitudinal edge (127)is drawn onto the longitudinal edge (127), whereupon this lower profiletogether with ist shim liner (134) is pressed together with the upperprofile which is formed as a mirror image and is also provided with ashim liner (135), the left-hand longitudinal rim (120) of the lowerprofile is bent upwards around the top edge of the shim liner (135) andits longitudinal rim (120) provided with the dovetailed groove ispressed into the upper side of the shim liner (135) and around thelongitudinal edge (133) of the upper profile, which longitudinal edge isembraced by the rib (137), whereas, at the same time, the right-handlongitudinal rim (128) of the upper profile is bent downwards around thetop edge of the shim liner (134) and its longitudinal rim (128) providedwith the dovetailed groove is pressed into the lower side of the shimliner (134) and around the longitudinal edge (127) of the lower profile,which longitudinal edge is embraced by the rib (136) of the shim liner.

10. Device for the performance of the method according to claim 1 withat least two working paths and, along them, installations for formingthe metal bands into profiles, characterized by a drawing stationlocated at the end of the device, which drawing station is adapted to atleast one profile to be manufactured and serves for the simultaneousdrawing of at least two metal bands off the magazine rolls and theirmoving along the pertaining working paths through the nondriven forminginstallations located there for the forming of metal bands inlongitudinal direction, through a greasing station located before theforming installations, and through further, non-driven forminginstallations to the strengthening of the longitudinal rims of the metalbands by means of folded welts.

11. Device according to claim 10, characterized by a pair of rollersacting on one longitudinal rim of the metal bands, for coining, knurlingor perforating.

12. Device according to claim 10, characterized by a drawing stationthat is movable from a firm initial position to an adjustable endposition, on reaching the end position effects the switching on of aseparating device for the finished product, then returns automaticallyto its initial position and grasps the end of the profile, whereupon thewhole cycle of movement repeats itself.

13. Device according to claim 10, characterized by a stationary drawingdevice with endless drawing chains running over guiding and drivingwheels, which are provided with profile-gripping claws, under springaction, with elastic buffers for gripping the profile to be manufacturedfrom at least two sides.

14. Device according to claim 13, characterized by profile-grippingclaws and puffers located on the levers inclined towards the profileerection for the obtention of a clamping effect of theseprofile-gripping claws on the profile gripped by exerting a pushingforce on the profile.

15. Device according to claim 13, characterized by a separating devicefollowing the profile moved, for straight cuts and cuts in miter atangles adjustable to the profile.

16. Device according to claim 10, characterized by forming installationsconsisting of profile mill cutters, each of which is mounted freelyrotating on the front end of a carrying bolt (70, 71, 72, 73), the rearpart of which is held in a socket (74, 75, 76, 77) which is fixed oncolumns and is vertically adjustable to the axis of the bolt for thepurpose of adjusting the bolt and the profile mill cutters carried by itrelatively to the other carrying bolts mounted on the same columns (78,79).

17. Device according to claim 10, characterized by multiple-part profilemill cutter whose single parts are rotatable on a carrying bolt freelyand independently of each other.

18. Device according to claim 10, characterized by forming rollers (12,13, 14 and 17, l8, 19 respectively) located along the first workingpath, three of which are in each case disposed, with their axes ofrotation inclined towards each other, on-a plane vertical to the metalband running through, during which process the central rollers (13, 18)of each group of three have an axis of rotation parallel with thesurface of the metal band and act together with the forming cores (15,23) or forming rollers (45, 46, 46', 46"), corresponding in each case tothe form of the profile, under the metal band, whereas the lateralrollers (12, 14) show an increasing diagonal position of their axes andthe last of the groups of three form a split between the three rollerson the one hand and between the forming core or forming roller on theother, which split corresponds to the desired profile of the metal band.

19. Device according to claim 18, characterized by analogous groups offorming rollers, located along a second working path, whose last groupof three forms a split corresponding to a second profile of metal bandwhich is difi'erent from the first profile.

20. Device according to claim 19, characterized by a disposition of thesecond working path vertically below the first working path.

21. Device according to claim 10, characterized by a threading devicelocated on at least one working path (1) behind the forminginstallations (17, 18, 19), consisting of sheet-metal deflectors (35,36) for drawing a profiled shim liner (33, 34) onto the longitudinalrims (21, 22) ofa formed metal band (4).

1. Method for making up at least two metal bands into a hollow rail bymeans of roll forming tools and by joining the lateral edges by means offolded welts, characterized by the fact that the metal bands aresimultaneously drawn through the rotating forming tools by a tractiveforce acting from the formed end, in the roll forming tools withoutadvance force they are formed into profiles only by a pressure acting onthe surface of the bands and at the same time under the effect of thelongitudinal feed they are strengthened in at least some zones of theirstructure and thereby straightened, the longitudinal edges of at leastone of the profiles are provided with a nonmetallic elastic shim linerand then the profiles are pressed together, bordered on at least one oftheir longitudinal edges and without metallic contact frictionallyconnected with one another between the longitudinal edges embracing oneanother by means of a folded welt embracing the shim liner all round,which folded welt is under initial stress and secured against transverseforces, and thus the hollow rail is made in one operation.
 2. Methodaccording to claim 1, characterized by the fact that the metal bands arein each case drawn forward by the tractive force on a stretch determinedin advance and formed into the proposed hollow rail, which is thenseparated, and hereupon the cycle of operation is automaticallyrepeated.
 3. Method according to claim 1, characterized by the fact thatthe metal bands are continuously drawn forward and formed into theproposed hollow rail from which each time a predetermined length isseparated without interruption of the drawing process.
 4. Methodaccording of claim 1, characterized by the fact that the elastic shimliner is fed to the metal bands in the form of a profile and united withthe longitudinal edges of one band.
 5. Method according to claim 1,characterized by the fact that at least one of the bands is providedalready before, or during, its forming with an elastic coating on itslongitudinal edges.
 6. Method according to claim 1, characterized by thefact that the longitudinal edges of at least one of the bands isprovided with rugosities, in particular with knurling or perforation. 7.Method according to claim 1, characterized by the fact that the upper(4) of two metal bands (4, 5) moved one beneath the other is formed intoa U profile open downwards and the two legs are chamfered outwards 90*(21, 22), during which process the underneath metal band (5) istransformed into a lower and narrower U profile with wider longitudinalrims chamfered outwards (26, 27), then a shim liner consisting of anelastic band doubled longitudinally (33, 34) is drawn onto each of therims (21, 22) turned outwards of the upper U profile, the lower parts ofthe shim liner protruding inwards above the chamfered edge up to itsend, the aforesaid two U profiles are pressed upon one another and therims (28, 29) of the lower U profile are bent approx. 180* around thelongitudinal rims (21, 22) of the upper U profile, which longitudinalrims are coated with the shim liner, and then pressed into the elasticshim liners (33, 34) which are enclosed all round.
 8. Method accordingto claim 1, characterized by the fact that the upper (100) of two metalbands (100, 101) moved one beneath the other is formed into a U profileopen downwards, the two legs of which are chamfered outwards 90* attheir lower ends and at their outer rims (104, 105) are further bentupwards 90*, then a band-shaped elastic shim liner (102, 103) with awide base plate and hook-shaped protruding ribs (106, 107) embracing therims (104, 105) is drawn onto the rims (104, 105), during which processthe lower metal band (10) is formed into a broad U profile open abovewith upright longitudinal rims (108, 109) which are both bent outwards90* and by two further nearly rectanagular folding welts are providedwith a U-shaped groove (110, 111), then they are further bent around theinside edges (112, 113) and set vertically, the aforesaid U-shapedgrooves are then compressed into dovetailed grooves (114, 115) andflanged outwards on the longitudinal edges (114, 115), hereupon thelower U profile is pressed against the base plates of the shim liners(102, 103), which are on the longitudinal rims (104, 105) of the upper Uprofile, the longitudinal rims (108, 109) of the lower U profile arebent upwards around the two top edges of the base plates and the twolongitudinal rims (108, 109) provided with the dovetailed grooves (114,115) are pressed into the upper sides of the shim liners (102, 103) andaround the longitudinal edges (104, 105) of the upper profile, which areembraced by the ribs (106, 107) of the shim liners.
 9. Method accordingto claim 1, characterized by the fact that two metal bands (118, 119)moved one beneath the other are simultaneously formed into the mirrorimage of one another, during which process the lower metal band (118) isbent upwards 90* at its left-hand longitudinal rim (120) (FIG. 32) andthis leg is further bent outwards 90*, by two further rectangularchamferings is provided with a U-shaped groove (122), by further bendingaround its chamfered inner edge (123) is righted again, the U-shapedgroove is compressed into a dovetailed groove (124) and the outermostedge of the leg (125) is bent inwards, whereas the metal band (118) ischamfered downwards 90* at the right-hand longitudinal rim and thentogether with this leg (121) bent over 90*, put vertically and flangeddownwards 90* At the outermost longitudinal edge (127), then aband-shaped elastic shim liner (134) with a wide base plate and ahook-shaped protruding rib (136) embracing the longitudinal edge (127)is drawn onto the longitudinal edge (127), whereupon this lower profiletogether with ist shim liner (134) is pressed together with the upperprofile which is formed as a mirror image and is also provided with ashim liner (135), the left-hand longitudinal rim (120) of the lowerprofile is bent upwards around the top edge of the shim liner (135) andits longitudinal rim (120) provided with the dovetailed groove ispressed into the upper side of the shim liner (135) and around thelongitudinal edge (133) of the upper profile, which longitudinal edge isembraced by the rib (137), whereas, at the same time, the right-handlongitudinal rim (128) of the upper profile is bent downwards around thetop edge of the shim liner (134) and its longitudinal rim (128) providedwith the dovetailed groove is pressed into the lower side of the shimliner (134) and around the longitudinal edge (127) of the lower profile,which longitudinal edge is embraced by the rib (136) of the shim liner.10. Device for the performance of the method according to claim 1 withat least two working paths and, along them, installations for formingthe metal bands into profiles, characterized by a drawing stationlocated at the end of the device, which drawing station is adapted to atleast one profile to be manufactured and serves for the simultaneousdrawing of at least two metal bands off the magazine rolls and theirmoving along the pertaining working paths through the non-driven forminginstallations located there for the forming of metal bands inlongitudinal direction, through a greasing station located before theforming installations, and through further, non-driven forminginstallations to the strengthening of the longitudinal rims of the metalbands by means of folded welts.
 11. Device according to claim 10,characterized by a pair of rollers acting on one longitudinal rim of themetal bands, for coining, knurling or perforating.
 12. Device accordingto claim 10, characterized by a drawing station that is movable from afirm initial position to an adjustable end position, on reaching the endposition effects the switching on of a separating device for thefinished product, then returns automatically to its initial position andgrasps the end of the profile, whereupon the whole cycle of movementrepeats itself.
 13. Device according to claim 10, characterized by astationary drawing device with endless drawing chains running overguiding and driving wheels, which are provided with profile-grippingclaws, under spring action, with elastic buffers for gripping theprofile to be manufactured from at least two sides.
 14. Device accordingto claim 13, characterized by profile-gripping claws and puffers locatedon the levers inclined towards the profile erection for the obtention ofa clamping effect of these profile-gripping claws on the profile grippedby exerting a pushing force on the profile.
 15. Device according toclaim 13, characterized by a separating device following the profilemoved, for straight cuts and cuts in miter at angles adjustable to theprofile.
 16. Device according to claim 10, characterized by forminginstallations consisting of profile mill cutters, each of which ismounted freely rotating on the front end of a carrying bolt (70, 71, 72,73), the rear part of which is held in a socket (74, 75, 76, 77) whichis fixed on columns and is vertically adjustable to the axis of the boltfor the purpose of adjusting the bolt and the profile mill cutterscarried by it relatively to the other carrying bolts mounted on the samecolumns (78, 79).
 17. Device according to claim 10, characterized bymultiple-part profile mill cutter whose single parts are rotatable on acarrying bolt freely and independently of each other.
 18. Deviceaccording to claim 10, characterized by forming rollers (12, 13, 14 and17, 18, 19 respectively) located along the first working path, three ofwhich are in each case disposed, with their axes of rotation inclinedtowards each other, on a plane vertical to the metal band runningthrough, during which process the central rollers (13, 18) of each groupof three have an axis of rotation parallel with the surface of the metalband and act together with the forming cores (15, 23) or forming rollers(45, 46, 46'', 46''''), corresponding in each case to the form of theprofile, under the metal band, whereas the lateral rollers (12, 14) showan increasing diagonal position of their axes and the last of the groupsof three form a split between the three rollers on the one hand andbetween the forming core or forming roller on the other, which splitcorresponds to the desired profile of the metal band.
 19. Deviceaccording to claim 18, characterized by analogous groups of formingrollers, located along a second working path, whose last group of threeforms a split corresponding to a second profile of metal band which isdifferent from the first profile.
 20. Device according to claim 19,characterized by a disposition of the second working path verticallybelow the first working path.
 21. Device according to claim 10,characterized by a threading device located on at least one working path(1) behind the forming installations (17, 18, 19), consisting ofsheet-metal deflectors (35, 36) for drawing a profiled shim liner (33,34) onto the longitudinal rims (21, 22) of a formed metal band (4).